Fabric with variant-height tufis and method



Oct. 8, 1957 E. MQRGAN ETAL FABRIC WITH VARIANT-HEIGHT TUFTS AND METHOD Filed Sept. 15, 1954 2 Sheets-Sheet l IDW \N MOQGAN ancl THEODORE C. SI'PPEL.

INVENTORSv w fm ATTORNEYS Oct. 8, 1957 E. MORGAN ETAL 2,808,855

FABRIC WITH VARIANT HEIGHT TUFTS AND METHOD Filed Sept. 15, 1954 2 Sheets-Sheet 2 INVENTORfi EDwm M0126 AN and THEODORE C. SIPPEL ATTORNEYS:

Patented Oct. 8, 1957 FABRIC WITH VARIANT-HEIGHT TUFTS AND METHOD Edwin Morgan and Theodore C. Sippel, Laurinburg, N. C., assignors to Scotland Mills, Incorporated, Laurinburg, N. C., a corporation of North Carolina Application September 13, 1954, Serial No. 455,716

6 Claims. (Cl. 139-392) This invention relates to tufted fabrics, such as chenille and the like, and it is an object of this invention to provide an improved fabric comprising a base of interwoven relatively fine warp yarns and weft yarns and having spaced parallel rows of relatively large tufts thereon between which spaced rows other intervening spaced rows of relatively small tufts of approximately half the size of the first-named tufts are formed.

It is another object of this invention to provide a base fabric having spaced rows of variant height tufts thereon which are formed by recurrently floating groups of relatively heavy yarns upon the surface of the base fabric and tying the yarns in some rows to the base at predetermined spaced intervals while tying the yarns in other rows to the base fabric at intervals substantially half of the length of the intervals between the points at which the first-named groups of yarns are tied into the fabric whereby the floats in adjacent rows are so spaced that the fabric is particularly adaptable for use with automatic machinery for cutting the floats in the course of formation of tufts therefrom and so the tufts in said adjacent rows may be of one size in one row and may be of a size in the second row substantially twice that of the size of the tufts in the adjacent row.

It is another object of this invention to provide an improved tufted fabric and method of making same comprising a woven base having spaced first and second groups of recurrently floated tuft-forming yarns arranged on one face of the base, wherein the tuft-forming yarns in the first groups are secured to the base fabric at given spaced intervals thereby defining floats of a given length and wherein the tuft-forming yarns in the second groups are secured to the base fabric at spaced intervals substantially equal to one half the length of said given intervals and the points of securement of the first and second groups of tuft-forming yarns being such that alternate floats in the second groups are substantially centrally alined with each successive float in the first groups and intervening floats in the second groups are substantially centrally alined with the points of securement of the yarns in the first groups whereby, upon alternate movements of an automatic cutting device across the rows of floats, floats in both the first and second groups of tuft-forming yarns will be severed and, upon intervening movements of the cutting device, only floats in the second groups will be severed, since the cutting device will pass over the binder yarns or points of securement at the junctures of adjacent large floats in the first groups.

As a result, after the floats have been cut and the fabric has been subjected to a liquid treatment such as washing and tumbling, dyeing and the like, rows of spaced tufts are formed of the first groups of yarns, which tufts are substantially twice the size or height of each of the spaced tufts formed of the second groups of yarns.

Some of the objects of the invention having been stated, other objects will appear as the description proceeds when taken in connection with the accompanying drawings, in which Figure 1 is a somewhat diagrammatic view of the improved fabric showing the manner in which the floated tuft-forming yarns are arranged thereon;

Figures 2 and 3 are greatly enlarged sectional views taken substantially along the respective lines 22 and 3-3 in Figure l and showing the relative lengths of the floats and the relative positions of the portions of base fabric yarns employed as binder yarns in adjacent rows of variant-length floats;

Figure 4 is a somewhat diagrammatic view of the por-- tion of fabric shown in Figure 1, after the floats thereof have been severed and before the fabric has been washed and tumbled or otherwise treated;

Figure 5 is a view similar to Figure 4 showing the rows of variant-height tufts on the base fabric produced by floating and cutting tuft-forming yarns as shown in Figures 1 and 4 and then subjecting the fabric to a washing and tumbling operation or other liquid treatment.

Referring more specifically to the drawings, the numeral 10 generally designates a suitably woven base fabric or ground fabric which is preferably, but not necessarily, woven from relatively fine weft and warp yarns such as are generally indicated at F and W, respectively, in Figures 2 and 3. A detailed description of the ground or base fabric 10 is deemed unnecessary, since there are many different ways in which the ground fabric could be constructed and the yarns F and W may be of any desired textile material. The ground warp yarns W and ground filling yarns F may be interwoven in any usual way so as to produce a plain weave, twill, sateen or any other desirable base as ground fabric.

As the ground fabric 10 is Woven, spaced first and second groups of tuft-forming yarns 11 and 12 are connected thereto at spaced intervals, which connection is established by interweaving the groups of tuft-forming yarns 11 and 12 with certain yarns in the base fabric which, for convenience, will be hereinafter designated as binder yarns or threads or points of securement. The binder yarns or threads which serve to attach the spaced first groups of tuft-forming yarns 11 to the base fabric 10 are indicated at 13 and the binder yarns or threads which serve to attach the spaced second groups of tuftforming yarns to the base fabric 10 are indicated at 14. The binder yarns 13 define relatively long floats 15 therebetween and the binder yarns 14 define relatively short floats 16 therebetween.

The cross-sectional area of, or the number of yarns in, each of the first rows of yarns 11 is substantially greater than the cross-sectional area of, or the number of yarns in, each of the second rows of yarns 12. Assuming all of the tuft-forming yarns to be of the same size and texture, it is preferable that the number of yarns 11 in each first group is twice that of the number of yarns 12 in each second group. As illustrated in Figures 1 and 4, there are four tuft-forming yarns in each first group 11 and two tuft-forming yarns in each second group 12, although the number of yarns in each group 11 and 12 may be varied according to the size tufts desired.

In this instance, the first and second groups of tuftforrning yarns 11 and 12 are shown extending warpwise of the base fabric 10 and it is apparent that weft yarns or filler yarns serve as the binder yarns or threads 13 and 14 for the respective first andsecond groups of tuftforming yarns. However, it is apparent that the first and second groups of tuft forming yarns 11 and 12 may extend weftwise of the fabric, in which instance the binder yarns 13 and 14 would be comprised of warp yarns instead of weft yarns.

It will be noted intFigures 1 to 4, inclusive, that the binder threads or yarns 13 for each first group of tuftforming yarns 11 are disposed in substantially greater spaced relationship than are the binder threads or yarns 14 for each second group of tuft-forming yarns 12. As a matter of fact, the distance between adjacent binder threads or yarns 13 is approximately twice the distance between adjacent binder threads 14 and it will also be noted that the sets of binder threads 13 in each instance are disposed in staggered relation to the sets of binder threads 14.

As a result, the binder threads 13 for the first groups of tuft-forming yarns 11 are a'lined or substantially alined with the central portions of the floats formed between alternatepairs of binder threads or yarns 14 while the central portion of each float formed between adjacent binder threads 13 in the groups 11 are disposed in alinement with the central portions of intervening relatively short floats in said second groups of tuft-forming yarns 12.

In Figure l, the broken lines indicated at C-1 represent alternate lines along which suitable knives or other cutting devices, sever or cut the groups of tuft-forming yarns 11 and 12 in substantially straight lines without penetrating or cutting the base fabric 10. On the other hand, the broken lines C2 indicate intervening lines along which suitable knives or other cutting devices cut or sever the tuft-forming yarns 12 without penetrating or cutting the base fabric 10.

It will be seen that, when knives cut along the alternate lines indicated at C-1, alternate floats 16 of the second groups of tuft-forming yarns 12 are severed intermediate their ends and immediately adjacent floats 15 of the first groups of tuft-forming yarns are severed or cut intermediate their ends, thus forming respective short and long free-end float portions 17 and 18 (Figure 4). However, when knives out along the intervening lines -2, the intervening floats 16 of the second groups of tuftforming yarns 12 are severed substantially midway there of while the knives merely pass over the binder'threads 13 at the junctures of adjacent floats 15 of the first groups of tuft-forming yarns 11 without severing the same.

Thus, relatively long free-end portions 18 (Figure 4) are formed on each side of each set of binder threads 13 in each of the spaced first groups of tuft-forming yarns 11 while relatively short free-end yarn portions 17 are formed on each side'of each set of binder threads 14 in each of the spaced second groups of tuft-forming yarns 12. Since the tuft-forming yarns 11 and 12 are attached to the base fabric 10 under relatively light tension, upon the floats being severed, it will be noted in Figure 4 that the float sections 17 and 18 flare outwardly and their cut edges arespaced'slightly from each-other because of the tension therein being relaxed.

The tuft-forming yarns 11 and 12 are preferably made i from a soft, fluffy and loosely twisted material, but may be made from any desired textile material so that, after the cutting operation takes place, leaving the fabric then in the condition shown in Figure 4, the fabric is subjected to a suitable liquid treatment, such as washing and tumbling, dyeing or is otherwise treated and, when these treatments are completed and the fabric is dried, the finished product shown in Figure 5 results wherein the float sections 17 and 18 stand up from the base fabric in the form of tufts.

Referring to Figure 5, it will be noted that the rows of spaced tufts 18 are substantially larger or higher relative to the base fabric 10 than the rows of spaced relatively small tufts 17 and the distance between adjacent tufts in each row is proportionate to the size of the tufts so that there are, in this instance, two of the relatively small tufts 17 for every'single large tuft 18 and it will be noted that there are two of the relatively small tufts 17 spaced each side of the lateral plane of each of the relatively large tufts 18 thereby producing a very pleasing ornamental effect. I

Although all of the tufts in any single row are shown 'as being of the same size or substantially the same size, it is apparent that tufts, like the tufts 17, may be inter- "uiuin'gled with and in a same row as tufts of the character of the relatively large tufts 18 and sections of adjacent rows may have tufts of the same size in each row while other adjacent sections of these same adjacent rows may have variant sizes or heights of tufts therein to produce various ornamental designs. Also, the ornamental appearance of the finished fabric may be further enhanced by dyeing the various groups of tuft-forming yarns 11 and 12 different colors. The gro'ups'll and 12 may be arranged in any desired sequence. That is, there may be a'single'la'rge-tuft group 11 or several spaced groups 11 between adjacent small-tuft groups 12 and vice versa, according to any preconceived pattern.

It is thus seen that we have provided an improved tufted fabric "and met hod of forming the same wherein first spaced or separate groups and second spaced or separate groups of parallel tuft-forming yarns are located on the base fabric and the spaced first groups are composed of a substantially greater 'number of yarns than each'of the spaced second groups. The spaced first groups of tuftforming yarns are tied into the base fabric by binder threads 13 spaced substantially from each other and the spaced second groups of tuft-forming yarns are tied into the fabric by binder yarns 14 which are spaced approximately half as far apart from each other as are the binder threads 13 and, in addition, the binder yarns 14 are disposed in staggered or ofl-setrelation with respect to the binder yarns 13.

Accordingly, the improved fabric facilitates the cutting of tufts so that upon alternate movements of the cutting means transversely of the tuft-forming yarns, alternate floats or floated portions of the yarns in the second groups 'are severed while immediately adjacent floats or floated portions of the yarns in the first groups are severed. On the other hand, upon intervening strokes of the cutting means transyersely of the tuft-forming yarns, the floated portions of the yarns in the second groups intervening between said alternate floated portions thereof are severed while'the cutting means merely pass over the portions of the tuft-forming yarns in the first groups which are bound to the base fabric so the yarns in the first groups are not severed upon said intervening movements of the cutting means. v

7 Thus, after the tuft-forming yarns have been cut and the fabric subjected to a suitable liquid treatment or treatments and dried, rows of spaced relatively small tufts .17 result from the second groups of tuft-forming yarns 12 and rows of substantially spaced relatively large tufts 18 result from the spaced first groups of tuft-forming yarns 11, and all of the tufts are spaced sufliciently from each other to expose the ground fabric 10 therebetween.

It is apparent that the maximum lengthsor heights of tufts which will stand up or project outwardly from the base fabric depends upon the texture or bulkiness of the tuft-forming yarns and the number of such yarns in each of the spaced groups 11 and 12. The area of the ends "of the tufts is also determined by the same factors as those determining the maximum lengths or heights of tufts, although the areas of the ends of the tufts are not limited to being substantially equally proportionate to their lengths.

For example, the same number of yarns may be used I in each of certain adjacent groups 11 and 12 and, while the end areas of all the resulting tufts 17 and 18 would then be substantially the same, the tufts 17 would still be of less height or length than thetuftslS. In other words the sizes of the tufts are determined by the lengths of the floats and the bulkiness of the yarns in each group.

The term liquid treatment as used throughout the specification and the appeiided claims is to be cohstr ued as any treatment in which the fabric is moistened o r saturated sufficiently to shrink'the tuft-forming yarns and the base fabric so the tufts will stand up or bunch up as shown in Figure 5. This liquid treatment may include any of the usual types of dyeing processes or washing and tumbling, or subjecting the product to steam, etc., after which the fabric is dried.

In the drawings and specification there has been set forth a preferred embodiment of the invention, and although specific terms have been employed they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being defined in the claims.

We claim:

1. A method of making a tufted bedspread fabric which comprises locating spaced parallel first and second groups of yarns on a base fabric while tying the spaced first groups of yarns to the base fabric at given spaced intervals to form long floats therebetween and tying the spaced second groups of yarns to the base fabric at second spaced intervals substantially onehalf the length of the first spaced intervals to form short floats between the second spaced intervals and wherein the first spaced intervals substantially bisect the space between certain of adjacent second spaced intervals, thereafter cutting the floated portions of the first and second yarns transversely thereof by cutting alternate floated portions of the second spaced groups of yarns with alternate movements of the cut-ting means while cutting immediately adjacent floats of the first groups of yarns and by cutting intervening floats of the second groups of yarns along paths alined with the upper surfaces of the tie-in points of the first groups of yarns whereby tufts are formed wherein substantially twice the number of tufts are formed from the second groups of yarns than are formed from the first groups of yarns, and then subjecting the fabric to a liquid treatment to cause said tufts to stand out from the base fabric.

2. A method of making a tufted bedspread fabric which comprises weaving a base fabric while locating a plurality of spaced first and second rows of tuft-forming yarns thereon wherein there are twice as many tuft-forming yarns in the first rows as there are in the second rows, tying the first yarns to the base fabric at first uniformly spaced intervals, tying the second yarns to the base fabric at second uniformly spaced intervals and wherein the second uniformly spaced intervals are substantially half the size of the first uniformly spaced intervals, thereafter severing the tuft-forming yarns in adjacent rows intermediate the points at which the tuft-forming yarns are tied into the fabric whereby free-end portions of the first and second tuft-forming yarns are formed each side of the respective intervals, thereafter subjecting the fabric to a liquid treatment to cause the free-end portions of said tuft-forming yarns each side of each of the tie-in points to project outwardly in the form of a tuft and whereby the tufts formed from the first spaced rows of yarns are spaced a substantially greater distance from each other than are the tufts formed from the second rows of yarns and whereby the tufts formed from the first rows of yarns are substantially twice the height of the tufts formed from the second rows of yarns relative to the face of the base fabric.

3. A method of making a tufted bedspread fabric which comprises locating spaced parallel first and second groups of yarns on a base fabric while tying the spaced first groups of yarns to the base fabric at given spaced intervals and tying the spaced second groups of yarns to the base fabric at second spaced intervals of substantially less length than the first spaced intervals and wherein the first spaced intervals substantially bisect the space between certain of adjacent second spaced intervals, thereafter cutting the portions of the first and second yarns disposed between adjacent spaced intervals transversely thereof whereby tufts are formed wherein a substantially greater number of tufts are formed from the second groups of yarns than are formed from the first groups of yarns, and then subjecting the fabric to a liquid treatment to cause said tufts to stand out from the base fabric.

4. A method of making a chenille bedspread fabric which comprises locating spaced, parallel first and second groups of yarns on a base fabric while securing the spaced first groups of yarns to the base fabric at given spaced intervals and securing the spaced second groups of yarns to the base fabric at second spaced intervals substantially one-half the length of the first spaced intervals and wherein the first spaced intervals substantially bisect the spaces between certain of adjacent second spaced intervals, thereafter cutting the first and second yarns substantially mid: way of their points of securements transversely thereof whereby tufts are formed wherein substantially twice the number of tufts are formed from the second groups of yarns than are formed from the first groups of yarns.

5. A method of making a chenille bedspread fabric which comprises locating spaced, parallel first and second groups of yarns on a base fabric while securing at least a section of at least one of said first groups of yarns to the base fabric at first spaced intervals and securing an adjacent section of at least one of said second groups of yarns to the base fabric at second spaced intervals of substantially less length than said first intervals and wherein the points of securement of the first group of yarns are disposed substantially midway between certain adjacent pairs of points of securement of said adjacent section of said second group, and thereafter cutting said sections of the first and second groups of yarns substantially midway of their respective points of securement transversely thereof to form tufts therefrom.

6. A chenille bedspread fabric comprising a woven base fabric having a plurality of spaced substantially parallel rows of tufts projecting from at least one face thereof, there being twice as many tufts in a given length of fabric in certain of said rows as there are in certain other rows, the tufts in the first-named certain rows being substantially half the height of the tufts in said other certain rows, the tufts in the first-named certain rows being spaced substantially equidistant from each other, the tufts in said other certain rows being spaced equidistant from each other but substantially twice as far apart as the tufts in the first-named certain rows, and adjacent rows being spaced apart a distance at least as great as the height of the tufts in the first-named certain rows.

References Cited in the file of this patent UNITED STATES PATENTS 1,319,710 Hope Oct. 28, 1919 1,484,292 Boyd Feb. 19, 1924 1,871,249 Waite Aug. 9, 1932 2,087,770 Goulet July 20, 1937 2,110,866 Castles Mar. 15, 1938 2,117,954 Greenwood May 17, 1938 2,187,469 Carragher Jan. 16, 1940 2,681,083 Dacey June 15, 1954 2,685,894 Parlin Aug. 10, 1954 FOREIGN PATENTS 590,655 Great Britain July 24, 1947 

